Performance

Spotlight

San Jose Mercury News:

Compressed Air System Upgrade Increases Effi ciency and 

Saves Energy at a Newspaper Plant

Project Summary

In August 2004, the San Jose Mercury News, Inc., fi nished upgrading the 

compressed air system at its printing facility in San Jose, California. Before the 

upgrade project, the compressed air systemʼs performance had become erratic and 

energy costs were on the rise. To improve the systemʼs effi ciency and performance, 

the Mercury News commissioned a system-level evaluation of the compressed 

air system by Air Perfection, a U.S. Department of Energy (DOE) Allied Partner. 

The assessment, which included an AirMaster+ analysis, was carried out by an 

Air Perfection employee who is also a Qualifi ed AIRMaster+ Specialist. The fi nal 

report provided AIRMaster+ estimates of potential energy savings and a systemlevel strategy to improve the system. This project resulted in a system with better 

compressor control, a lower leak load, more stable pressure levels, and improved 

air treatment. All these added up to better performance as well as energy savings. 

Plant/Project Background

The San Jose Mercury News, Inc., a Knight Ridder company, was founded in 1851. 

The newspaper maintains 13 bureau offi ces and has a daily circulation of 263,000 

readers. Circulation extends from San Francisco to Monterey. The San Jose printing 

plant is a 410,000-square-foot building housing approximately 1,300 employees. 

The compressed air system at the San Jose facility includes six 100-horsepower 

rotary screw compressors. Because of fl uctuating air demand patterns, the systemʼs 

performance was erratic; all six compressors had to be operated at once to maintain 

consistent production levels. This operational pattern wasted energy and placed 

extra stress on end-use equipment. In the system-level review, the Qualifi ed 

AIRMaster+ Specialist found that air demand patterns could be controlled by 

increasing the storage capacity, improving compressor controls, and installing 

a pressure/fl ow controller. In addition, he determined that air quality could be 

improved by adding mist-eliminator fi lters and that the plantʼs compressed air load 

could be reduced by fi xing leaks. Plant personnel found that implementing these 

measures improved the performance of the compressed air system considerably. In 

addition to having a more consistent air supply and more stable pressure levels, the 

plant now needs to operate fewer compressors to satisfy its air demand. 

Benefi ts 

• Saves $96,000 annually

• Reduces annual energy 

consumption by 800,000 kWh

• Improves system performance

• Achieves a 16-month simple payback

Industrial Technologies Program 

Proven Tools and Practices to 

Increase Industrial System Energy Effi ciency

Applications 

Compressed air systems are 

found throughout industry, and 

they can consume a signifi cant 

portion of the electricity used by 

manufacturing plants. Using a 

system-level strategy to improve 

a compressed air system is the 

best way to enhance system 

performance, increase effi ciency, 

and save energy. 

Proven Tools and Practices to 

Increase Industrial System Energy Effi ciency
BestPractices is part of the Industrial 

Technologies Program, and it supports 

the Industries of the Future strategy. 

This strategy helps the country’s 

most energy-intensive industries 

improve their competitiveness. 

BestPractices brings together emerging 

technologies and energy-management 

best practices to help companies 

begin improving energy efficiency, 

environmental performance, 

and productivity right now.

BestPractices emphasizes plant 

systems, where significant efficiency 

improvements and savings can be 

achieved. Industry gains easy access 

to near-term and long-term solutions 

for improving the performance of 

motor, steam, compressed air, and 

process heating systems. In addition, 

the Industrial Assessment Centers 

provide comprehensive industrial 

energy evaluations to small- and 

medium-size manufacturers.

A Strong Energy Portfolio 

for a Strong America

Energy efficiency and clean, renewable 

energy will mean a stronger economy, 

a cleaner environment, and greater 

energy independence for America. 

Working with a wide array of state, 

community, industry, and university 

partners, the U.S. Department 

of Energy’s Office of Energy Efficiency 

and Renewable Energy invests 

in a diverse portfolio of energy 

technologies.

FOR ADDITIONAL INFORMATION, 

PLEASE CONTACT:

EERE Information Center

1-877-EERE-INF

(1-877-337-3463)

www.eere.energy.gov

Visit our home page at

www.eere.energy.gov/industry

Industrial Technologies Program

Energy Efficiency and Renewable Energy

U.S. Department of Energy

Washington, DC 20585-0121

Results

The compressed air system project at the San Jose plant is yielding impressive 

energy savings. Measurements of the systemʼs energy use since the project was 

completed indicate an annual energy savings of 800,000 kWh and a cost savings of 

$96,000. These savings are consistent with AIRMaster+ estimates. After the plant 

received a rebate from Pacific Gas & Electric, total project costs were $129,000. 

With total annual savings of $96,000, the project yields a simple payback of 

approximately 16 months. 

Lessons Learned

In many industrial plants that use compressed air, fluctuating system pressure is a 

frequent problem that is often misinterpreted as insufficient pressure. A common 

response is to bring additional compressors online to make up the perceived 

shortfall, which wastes energy. However, in most cases the pressure level can 

be stabilized without activating more compressors. By applying a system-level 

approach, industrial end-users can uncover the root cause of the pressure fluctuation 

and determine how to best stabilize system pressure. At the San Jose Mercury News 

plant, this approach uncovered several energy efficiency opportunities and led to 

the implementation of a project that optimized the systemʼs efficiency and yielded 

significant energy savings. Furthermore, the plant was able to satisfy its production 

parameters while operating fewer compressors. This methodology, which relied on 

AIRMaster+, can be successfully applied in many types of industrial plants that use 

compressed air.

Project Partners

San Jose Mercury News

San Jose, CA

Air Perfection

Dixon, CA

Pacific Gas & Electric Co.

San Ramon, CA

Specialist Profile

Dan McCoin is the manager of field service technicians at Air Perfection and has 29 years of experience working with compressed air 

systems. As an AIRMaster+ Qualified Specialist, he has been involved 

in dozens of successful compressed air system optimization projects 

that have yielded substantial energy savings. Dan has been particularly active in using AIRMaster+ to validate energy savings for local 

utility company rebate programs.

Qualified Specialists

Qualified Specialists are industry professionals who identify costcutting and efficiency opportunities in industrial plants. Experienced 

professionals who complete a qualification training workshop and exam 

for specific DOE-developed software tools receive special designations, 

and they can use these tools to help plants reduce costs, decrease 

maintenance and downtime, and improve productivity. The training 

recognizes and enhances a professional’s expertise in the use of DOE’s 

AIRMaster+ software tool, Pumping System Assessment Tool, Process 

Heating Assessment and Survey Tool, and Steam System Tools. 

For information, visit www.oit.doe.gov/bestpractices/software_tools.shtml.

Dan McCoin

DOE/GO-102005-2080

June 2005